Containers and their construction

ABSTRACT

Plastic containers, such as clothes hampers, constructed of plastic sidewalls and top and bottom walls, the walls being separately molded for permanent resilient interlocking assembly by the consumer to form a rigid, stable structure, thus being shippable in knock-down form for saving of shipping space.

Unite States Patent 1191 Bush 1 Sept. 18, 1973 [54] CONTAINERS AND THEIRCONSTRUCTION 2,838,197 6/1958 Wolff 220/4 R 1 L 1 1 2,212,122 12/122:$12.2??? 222/21:

a ey, FOREIGN PATENTS OR APPLICATIONS [22] 1970 845,392 8/1939 France217/16 [21] Appl. No.: 89,200

Primary Examiner-George E. Lowrance 52 us. (:1. 220/7, 217/16, 220/4 FAttorney-Stevens, Davis, Miller & Mosher [51] Int. Cl 865d 7/28, B65d11/18 [58] Field of Search 220/4 R, 6, 7, DIG. 25, [57] ABSTRACT 220/4F; 217/16 48 Plastic containers, such as clothes hampers, con- 5 6]References Cited structed of lasuc sidewalls and top and bottom walls,

the walls being separately molded for permanent res1l- UNITED STATESPATENTS ient interlocking assembly by the consumer to form a 3,047,1837/1962 Papa 220/4 R rigid, stable structure, thus being shippable inknock- Nlcholas .1 down form for saving of pace 1,169,328 1/1916Holtgrewe... 217/16 2,177,933 10/1939 Boeye 217/48 X 6 Claims, 12Drawing Figures PATENTEI] SEP] 8 I973 SHEEI 1 BF 7 I N VE N TOR P404 63Bus PATENTED 3E? 1 81975 SHEET 3 U? 7 INVENTOR R404 J! 5051/ mmwaflwATTORNEYS PATENTEU B 5 SHEET B [If 7 PATENTED SEN 81973 SHiET 5 0F 7Bananas nmmnnnm q Bananas UDDUUUU 3 333.33

EEEEECE UUDUUDU \K UDDUBDU UUUUUUU SUBBED-U CONTAINERS AND THEIRCONSTRUCTION The invention hereinafter described, and as it is broadlyconceived in its scope of usefulness, relates to containers. Theinvention is illustrated specifically by an embodiment thereof in commonhousehold use, namely, a clothes hamper. Such hampers and the likecomprise four upstanding sidewalls, a bottom and a top, which isnormally hinged to the back sidewall. The invention is concerned withthe provision of such hampers, and/or containers from preformed, e.g.,molded plastic wall pieces, the pieces being provided with interengagingportions adapting them for assembly without the need of nails, screws,adhesives or similar means commonly employed.

Briefly stated, the sidewalls are adapted to interlock with the bottomand top pieces by way of complementary resilient surfaces which surfacesmay be functionally described as providing male-female association. Inthe molding of the pieces, their interengaging portions are carefullydimensioned and shaped such that when pressed or snapped into theintended engaged position, the interfitting is most precise and theholding action from the engaged parts'is exceedingly high. In this way,the parts, or pieces, provide containers that are strongly held togetherand extremely rigid.

For practical purposes the containers of the invention are permanentlyassociated, although it is contemplated that the parts or pieces may bemolded so as to be disengageable; moreover, the pieces of the storageportion of the container, i.e., the box" itself may be designed forsubstantially permanent engagement whereas the top therefor may berelatively easily removable. In this way, the top may be easily removedfor access to the storage area and then replaced so as to again closeand seal the container.

As a result of this invention, a great many advantages accrue. A majoradvantage arises in that great savings in shipping space and costs arepermitted. Normally, storage cabinets, chests and the like are shippedalready assembled since when preassembled they are more readily saleableto the consumer who does not care to undertake the assembly task.Moreover, production costs can be substantially lower since preassemblylabor costs can be eliminated. Since the invention permits the provisionof most any of the general types of containers, it is readily possibleto produce a given standard type of container, or crate such as used inlive chicken shipping, from standard interchangeable pieces, which maybedisassembled and returned in minimum shipping space for reuse. Since thepieces are molded from plastic materials, they are easily cleanable,they are durable in all weather, they are strong, and painting is notnecessary. Compared to wood, they are extremely light in weight, yetstrong and durable. They are highly resistant to marring and breakagedamage in shipping and use. Moreover, the containers of this inventionmay be made substantially airtight, and entirely water tight, exceptperhaps under water pressure. They may be ofsuch gauge and type thatmost any substance may be transported or stored, substantiallyregardless of weight and chemical nature.

Productiontechnique may easily be such as to provide containers of wideselectivity in depth by providing the sidewalls of two or moreinterlocking vertical tiers. The variety of types of containers issubstantially unlimited while providing substantially the sameadvantages in all cases, or even additionaladvantages in certain typesof applications. For example, drawers for cabinet structures are notdimensionally affected due to humidity changes, and therefore they donot bind even though the fitting may be exceedingly close. Di-

mensional stability is exceedingly important in cabinetry. Many suitableplastics are exceedingly cheap and basic costs of the units produced isquite low, especially considering that milling, to a particular size andconfiguration, is eliminated.

Obviously, the finished products need not be rectangular; thus, incrossection they be as a hexagon or octagon etc., circular or eliptical,et. as a matter of design. The interior may readily be divided incompartments, and if desired such may be of variable dimensions.

Basically, the invention is one involving savings in shipping costs of awide variety of commercial and household containers due to knock downshipping, thus requiring minimum shipping; volume, while also permittingthe end user easy and quick assembly to form strong and rigidcontainers, which also may be substantially permanent assemblies, orthey may be readily disassembleable as a matter of choice. As will beappreciated, both of these basic considerations are important and bothhave long been in need of a solu-. tion that is satisfactory in thatboth demands are satistied in a manner that does not impose adisadvantage to the other.

The invention, illustrated with respect to a household storage hamper orchest, is further more particularly described in the drawings wherein:

FIG. 1 is a perspective view of an assembled hamper;

FIG. 2 is a sectional view taken on the line 2-2 of FIG. 1;

FIG. 3 is a view in perspective of three sidewalls of the unit of FIG.1, showing the sidewalls in collapsed position;

FIG. 4 is a plan view of the side walls separated from each other; i l

FIG. 5 is a top plan view of the bottom wall-pedestal of the hamper;

FIG. 6 is section view on the line 6-6 of FIG. 5;

FIG. 7 is a sectional view taken on the line 7-7 of FIG. 6;

FIG. 8 is a top plan view of a top wall-locking member;

FIG. 9 is a sectional view on the line 9-9 of FIG. 8; FIG. 10 is asectional view on the line 10--10 of FIG.

FIG. 12 is a vertical end sectional view, fragmentary in the height andwidth of the walls, thru the hamper shown in FIG. I, the parts as showbeing enlarged for clarity.

Referring to FIG. 1, numeral 20 denotes the assembled hamper showing, inphantomlines, the lid or top in open position. Numeral 22 denotes thebase or pedestal piece (note FIG. 7, therebelow Numerals 24 and 26denote side and front walls, respectively. Numeral 28 and 30 seen inFIG. 12 denote the left end or side wall andthe back wall, respectively,and numeral 32 denotes the top closure piece.

As will be seen from FIG 12, the front wall 26 engages the bottompedestal 22 as shown at numeral 34, and wall 26 similarly engagestop-locking piece 36 (See also FIGS. 8 and 9) as shown at numeral 38.Sidewalls 24 and 28 entirely similarly engage the bottom pedestal FIG.11 is a sectional view on the line ll1l of a I side wall as shown inFIG. 4;

and the top locking piece in similar laterally extending channels.

Backwall 30 as shown in the drawings is a perforated ventilating panel,for example, of fibreboard. The perforations are denoted by numeral 40.As will be observed from FIG. 12, the lower edge of the back panel fitsinto groove 42 in the base pedestal and into groove 44 of the top walllocking member 36. As may be seen in FIG. 2, side walls 24 and 28 areprovided with grooves 46 and 48 which receive the vertical edges of theback panel. It will be observed that grooves 42, 44, 46 and 48 aresimplechannels and, in the embodiment of the invention as shown herein, therelationship of the back panel to the grooves is merely that ofinterfitting engagement, i.e., not the interlocking engagement that isillustrated at numerals 34 and 38, the latter to be described in detailhereinbelow. However, it is pointed out that the back panel may beentirely similar to the other sides as to material etc., and theengagement shown at numerals 34 and 38 may be employed therefor ifdesired.

Before proceeding to describe the manner of interengaging the severalpieces to provide locking together so as to provide a substantiallyunitary assembly, it is desired to remark for purposes of easierunderstanding that the top locking piece as illustrated is a generallyrectangular member which is last snapped into engagement with thesidewalls, and, as may be readily seen in FIG. 12, the top closure 32 ishingedthereto as shown at numeral 50. Numeral 52 denotes a slot in whichone wing of the hinge is fixed into position as by cementing inposition. FIG. 8 shows the top-locking'member 36in top plan view withthe top removed; and the positioning of the slots 52 is there showntogether with other detail and in relation to FIG. 9, which is asectional view. FIG. is also a related sectional view.

Again referring to FIG. 12, channels 54 in the base 22 are provided asstrengthening aids. In such context and function, channels 54 may bemore aptly described as ribs, though not continuous, extendinglengthwise and breadthwise of the bottom surface, forming somewhat of awaffle-iron pattern as illustrated in FIG. 7.

Referring now to FIGS. 3 and 4, the relationship of the sidewalls to thefront wall is shown. In FIG. 4, the three pieces are shown detached fromeach other and FIG. 3 shows them attached in hinged relationship.(Please also see FIG. 2 which provides a horizontal sectional viewrevealing the association in additional preciseness.) Edges v56, 58, 60and 62 form the vertical corners of the hamper when the panels areassembled.

The three wall peices are provided with slots 64, entirely similar toslot 44, in which the hinges are fixed, thus permitting folding of thethree pieces to a flat assembly requiring little space in shipping, aswell as easy association with the base when the user removes the partsfrom the shipping box (a total of only 4, i.e., base pedestal, thehinged sidewall assembly, the back panel and the top locking piece withtop hinged thereto) for assembly to form the hamper. As will be seenmore clearly hereinafter, the time required for the assembly task is notmore than a minute or so and the operation is the ultimate insimplicity. There is no such occurrence as a missing screw or fitting,or the application'of adhesives.

Referring now to FIGS. 5 and 6 and now turning to the description of thecomplementary interengaging and interlocking features of the invention,it will be noted that a channel or groove 66 is molded into the basepedestal 22, the channel extending continuously the length and breadthof the pedestal along three edges, i.e., front and right-left edges.(Back panel receiving groove is seen in FIG. 6 at numeral 44.) Thepreassembled outer walls as seen in FIG. 3 are received within channel6. Molding to provide a close or quite precise fit is desirable, andpreferably, the sidewall engaging surfaces should provide at least aslight pressure exertion throughout the engagement.

The locking engagement of the base pedestal and the outer wall assemblyis provided by complementary surfaces carried by the walls of thechannel 66 and the vertical edge surfaces of the outer wall assembly. Itis desired to point out before proceeding with such description that theparticular locking means hereinafter described is not in any sense to beunderstood as placing undue limitations upon the basic inventiveconcept. It will be clearly apparent that numerous different types ofinterlocking surfaces may be employed to effect the objects of theinvention. However, the form or type of engagement herein describedprovides excellent holding action and, insofar as the described hamperis concerned, it may be stated to be preferred, though it is notnecessarily better than many other forms of a similar nature, especiallywhen the variety of containers, etc., to which the invention extends isconsidered, and also whether the unit constructed is to be of adisassembleable type. 7 Referring first to the enlarged FIG. 12,attention is directed to the surface denoted by numeral 68 on the outervertical sidewall of channel 66. Attention is also directed to anentirely similar surface carried by top locking member 36 which isdenoted by numeral 70. The function of these two surfaces is the same,and therefore an understanding of one locking surface providesunderstanding of all. Surface 68 abuts against triangular surface 72. Aswill be seen, each abutting surface overlaps along a horizontal line orplane as indicated at numeral 74.

Referring to surface 68, which is somewhat in the nature of a detent,and hereinafter so described, attention is now drawn to FIGS. 5 and 6.As will be observed detents 68 are triangular protrusions positioned ata plurality of spaced points in channel 66. Complementary slots, orsockets, for each detent are provided in the lower generally verticaledge surfaces of the hinged wall assembly. In this regard reference ismade to FIG. 4. The said slots are there denoted by numeral 72. As willbe observed, eight slots are provided along the lower wall surfaces forcooperation with eight complementary detents in the base pedestal. Asimilar number of slots are provided along the top edge of the outerwall assembly for interlock with a similar number of similar slots intop locking unit 36.

The locking engagement is accomplished by gently forcing the lower wallsurfaces fully into the base pedestal channel beyond the point of thedetents, wh'ereupon the detents spring back into engagement with theircomplementary sockets. In assembly, the outer walls and the basepedestal are rigidly engaged.

The back panel 30 is next inserted in the channels heretofore described,the top locking member with closure top attached is next similarlypressed downward into similar locking engagement, whereupon assembly iscomplete. r

it will be apparent that the four pieces in preassembled form may beshipped in approximately one-third the space required for similar unitswhich at present are shipped fully assembled. This is an advantagegreatly soughtby manufacturers. Coupling this fact with the eliminationof complexity of the problem of assembly upon arrival at the place ofuse, the achievements of the invention are clearly evidenced.

Referring to space saving, the ultimate in savings occurs when the unitin assembled form is a cube and/or in the case where the bottom and topportions are of about the same dimensions as the end walls. It issurprising how many useable units closely approximate these dimensions.Consequently, use of the present invention does indeed result in a greatreduction in shipping volume. Nesting type of containers, for example,waste baskets, flower pots, etc., where the bottom dimension relative tothe top permits substantially complete nesting, afford a great saving involume. The present invention accomplishes the same for units whichcannot be nested. Moreover, this invention may be employed to provideconical walled containers and frustopyamidal container by simple moldingmodifications. Thus side panels need not be restricted to only thevertical.

As has been pointed out hereinabove, the embodiment of the inventionherein specifically described and illustrated is by no means to beunderstood as placing undue limitations on the broader inventiveconcept. in this connection it is desired to remark particularly withrespect to contemplated modifications.

if it is desired to eliminate the slip-in back panel and to construct acontainer which is more uniform on all sides, such may be accomplishedin several different ways. For example, the four sidewalls may becomposed of two pair panels each composed of an end wall and the otherof each pair constituting the two opposing walls, that is to say a. sideand back panel as one piece, and a side and front panel as the other. Insuch case the hinging would appear at diagonal corners in the assembly.in shipping, the two pair-panel would fold to occupy the same space asthe hamper components illustrated herein. In all other respects the unitwould be similar. Of course the base pedestal and top locking memberwould contain locking receiving channels continuously around theirperimeters.

Similarly the four (or more) walls may be entirely separate andunhinged. Depending upon the height of the units formed in these ways,it may be desirable to provide vertical groove detenttype interlockingto add to stability, especially if the gauge material is notparticularly selected and/or otherwise stabilized. Obviously eachsidewall may be molded with pinsockets which, when in position,interrelate to be vertically pinned together as the opposing wings of ahinge itself. Further, in some instances it may be desired that all sidepanels be hinged together, much as a folding screen. As will beobserved, in square units, folding is thus possible to the least volume,and only a small loss in space saving need occur if in a rectangularunit.

As is well known, plastics may be produced which can be molded toprovide rigidity in one direction while being capable of greatflexibility in others; more dimensional stability can be supplied byembedded reinforcing members, such as rods, and which would provideadded rigidity in one or more directions. This being entirely feasible,the invention contemplates molding the four sidewalls as one continuousunit which is of such flexibility that its opposite ends may be broughttogether to provide the vertical rectangular volume (or circular volumewhere the base and top closure means are circularly grooved). In suchcase, vertical stabilizers, if needed, are easily molded into the wallpiece. The ends so brought together may be provided with verticalinterlocking channels as herein described. For example, a rigid hassockunit may be easily formed in this manner; and as will be readilyappreciated, such unit may constitute merely the interior frame about,and to, which may be applied or attached via snap-in grooves, speciallyadapted upholstery pieces. As will be understood also, the outer wallsmay provide ventilation openings as in crates, etc.

It may be pointed out that the dletents and opposing pockets are notrestricted as to dimension or number, for example, along the runninglength of the grooves. Thus, they may be lengthened in size or increasedin number to increase the holding action. For that matter, thecooperating locking members may continue throughout the entirety of theengaging surfaces. The detent-socket overlap in the horizontal plane maybe increased, as should be obvious.

Thus, various specific designs may be employed to complement the needsof the container or type of unit which is desired to be produced. Withrespect to the configuration of the detent and. mating pocket, it shouldbe pointed out that the overlap in the horizontal plane, as at numeral74, adds greatly to the stability of the unit, especially when thegroove itself and the sidewall surface engaged therewith ;are square toeach other. The tendency to relative rotation of the engaging pieces isminimized. However, as pointed out above, the type of interlock may bevaried. For example, the receiving channel need not be square, rather itmay be a rounded semi-closed trough, i.e., providing a relatively narrowcontinuous slot thru which a complementary continuous rounded bead,molded into the panel edges, is forced to form a continuous lock. Aswill be obvious, in all cases the locking engagement is accomplished byforcing the receiving complement (or by squeezing the engaging piece) togreater opening dimension, it returning to its repose state when theengaging surface, i.e., the pockets or sockets 72, are in opposedrelation. The plastic therefore must possess the necessary resiliency aswell as rigidity to complete the lock.

In the embodiment illustrated and many other similar units, it iscontemplated, perhaps preferably, but not necessarily, that theinterlock will be such as to be only quite difficultly releasable. Thisis: believed to be preferred since in the first place there is littlereason in the majority of household type units to need a separable unit,and in the second place, assembly strength is re duced, though this iseasily sufficiently controllable. An exception to household units would,for example, be a trash container such as used in kitchens, sinceseparability would permit more thorough cleaning. Separability afterassembly may be quite easily controlled by altering the horizontaloverlap to an angular overlap, i.e., inclined to the horizontal. In thisway, general rigidity of the plastic is not required to be modified. Ofcourse, the extent of overlap is another variable in this connection.

The containers herein described may be made from any one of numerousplastics, and all components need not necessarily be of the sameplastic. Moreover, the components may be formed of such as stainlesssteel as may be desired in producing sanitary, hospital-type units. Asto plastics, polystyrene materials are excellent, and suitable polymersthereof are obtainable from numerous sources.

As should be understood, the container sidewalls may be provided withhinged doors for access to the interior from the front side as in anycabinet; moreover, the sidewalls may be provided with means to supportinterlocking shelving, for example as employed in kitchen floor and wallcabinetry.

As heretofore pointed out, the invention has innumerable possibilities.

What is claimed is:

1. A knockdown type of clothes hamper or the like formed from moldedrelatively rigid, but somewhat resilient plastic, said hamper beingcomprised of a front wall and having hingedly associated therewith twosidewalls, each of said walls having the top and bottom edge portionspreformed to provide an intumed flat flange surface constituting upperand lower rim portions and, immediately adjacent said rims one or morechannel-like depressions in the vertically extending surface of saidwalls, constituting the female member of interlocking means, saidchannels extending horizontally along the width of said walls;

an upstanding base member constituting a one piece pedestal and bottomwall, said base member having a generally U or square-shape grooveextending about its perimeter generally complementing said rims, andhaving one or more inwardly extending bulging portion on the outervertical wall thereof generally co-extensive with said channels adjacentsaid rims and constituting the male member of interlocking means, saidbulging portion being shaped, positioned and adapted to interlock withsaid channels in snap-in fashion when said rims on said walls arepositioned in adjoining relationship and pressed thereinto;

a top locking member of generally rectangular configuration and havinggrooves and bulging portion entirely similar to those in said baseextending coextensively with the upper rims of said walls, whereby whensaid locking member is pressed downwardly on said upper rims, saidlocking member and rims interlock to complete a unitary rigid structure;said hamper being provided with a back panel held in position in groovesin said sidewalls and base, and said locking member having a top closurehinged thereto.

2. The assembly as claimed in claim 1 wherein the male-female lockingparts provide an overlapping area lying along a horizontal plane, i.e.,a plane normal to the direction of insertion of the complementary part,whereby the locking engagements are rendered substantiallydisengageable.

3. The assembly as defined in claim 1 wherein the overlapping areas liealong a plane extending at an angle less than normal to the direction ofinsertion whereby said parts are rendered more easily separable.

4. The structure as claimed in claim 1 wherein the interlocking portionsare reversed respectively in said sidewalls, said base member andtop-locking member.

5. The assembly as claimed in claim 4 wherein the male-female lockingparts provide an overlapping area lying along a horizontal plane, i.e.,a plane normal to the direction of insertion of the complementary part,whereby the locking engagements are rendered substantiallydisengageable.

6. The assembly as defined in claim 4 wherein the overlapping areas liealong a plane extending at an angle less than normal to the direction ofinsertion whereby said parts are rendered more easily separable.

1. A knockdown type of clothes hamper or the like formed from moldedrelatively rigid, but somewhat resilient plastic, said hamper beingcomprised of a front wall and having hingedly associated therewith twosidewalls, each of said walls having the top and bottom edge portionspreformed to provide an inturned flat flange surface constituting upperand lower rim portions and, immediately adjacent said rims one or morechannel-like depressions in the vertically extending surface of saidwalls, constituting the female member of interlocking means, saidchannels extending horizontally along the width of said walls; anupstanding base member constituting a one piece pedestal and bottomwall, said base member having a generally U or squareshape grooveextending about its perimeter generally complementing said rims, andhaving one or more inwardly extending bulging portion on the outervertical wall thereof generally co-extensive with said channels adjacentsaid rims and constituting the male member of interlocking means, saidbulging portion being shaped, positioned and adapted to interlock withsaid channels in snap-in fashion when said rims on said walls arepositioned in adjoining relationship and pressed thereinto; a toplocking member of generally rectangular configuration and having groovesand bulging portion entirely similar to those in said base extendingco-extensively with the upper rims of said walls, whereby when saidlocking member is pressed downwardly on said upper rims, said lockingmember and rims interlock to complete a unitary rigid structure; saidhamper being provided with a back panel held in position in grooves insaid sidewalls and base, and said locking member having a top closurehinged thereto.
 2. The assembly as claimed in claim 1 wherein themale-female locking parts provide an overlapping area lying along ahorizontal plane, i.e., a plane normal to the direction of insertion ofthe complementary part, whereby the locking engagements are renderedsubstantially disengageable.
 3. The assembly as defined in claim 1wherein the overlapping areas lie along a plane extending at an angleless than normal to the direction of insertion whereby said parts arerendered more easily separable.
 4. The structure as claimed in claim 1wherein the interlocking portions are reversed respectively in saidsidewalls, said base member and top-locking member.
 5. The assembly asclaimed in claim 4 wherein the male-female locking parts provide anoverlapping area lying along a horizontal plane, i.e., a plane normal tothe direction of insertion of the complementary part, whereby thelocking engagements are rendered substantially disengageable.
 6. Theassembly as defined in claim 4 wherein the overlapping areas lie along aplane extending at an angle less than normal to the direction ofinsertion whereby said parts are rendered more easily separable.